Integrated robotic 3d printing system for printing of fiber reinforced parts

ABSTRACT

A system for printing a three-dimensional object is provided. The system can include at least one print head configured to receive a continuous fiber and at least partially encase the continuous fiber with a formation material to create a composite material. The at least one print bed can be configured to move in at least six different degrees of freedom. The system can also include at least one print bed comprising a printing surface onto which the composite material may be selectively applied to form a work piece. The at least one print head can be positioned relative to the at least one print bed and configured to advance print media thereon.

PRIORITY INFORMATION

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/209,573 titled “Integrated Robotic 3D PrintingSystem for the Printing of Fiber Reinforced Parts” of van Tooren, et al.filed on Aug. 25, 2015, the disclosure of which is incorporated byreference herein.

BACKGROUND OF THE INVENTION

Additive manufacturing refers to any method for forming athree-dimensional (“3D”) object in which successive layers of materialare laid down according to a controlled deposition and solidificationprocess. The main differences between additive manufacturing processesare the types of materials to be deposited and the way the materials aredeposited and solidified. Fused deposition modeling (also commonlyreferred to as 3D printing) extrudes materials including liquids (e.g.,polymeric melts or gels) and extrudable solids (e.g., clays or ceramics)to produce a layer, followed by spontaneous or controlled curing of theextrudate in the desired pattern of the structure layer. Other additivemanufacturing processes deposit solids in the form of powders or thinfilms, followed by the application of energy and/or binders often in afocused pattern to join the deposited solids and form a single, solidstructure having the desired shape. Generally, each layer isindividually treated to solidify the deposited material prior todeposition of the succeeding layer, with each successive layer becomingadhered to the previous layer during the solidification process.

Unfortunately, while additive manufacturing technologies have becomemuch more common and less expensive in recent years, the technology isprimarily limited to formation of prototypes, as the formed materialsgenerally exhibit low strength characteristics. Attempts have been madeto form higher strength composite structures, for instance by combininga high crystalline polymer with a lower crystalline polymer in a fuseddeposition process. While such attempts have provided some improvementin the art, room for further improvement exists. For instance, thecharacteristics of highly crystalline polymers are still less than whatis desirable in many high strength applications.

What are needed in the art are methods for formation of high strengthcomposites according to an additive manufacturing process and thecomposites formed thereby.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

A system is generally disclosed for printing a three-dimensional object.In one embodiment, the system includes at least one print headconfigured to receive a continuous fiber and at least partially encasethe continuous fiber with a formation material to create a compositematerial. The system also includes at least one print bed comprising aprinting surface onto which the composite material may be selectivelyapplied to form a work piece.

The system may include, in particular embodiments, at least one printbed comprising a printing surface onto which print media is applied toform a work piece, with the at least one print bed being configured tomove in at least six different degrees of freedom. The at least oneprint head can be positioned relative to the at least one print bed andconfigured to advance print media thereon.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appended Figs.,in which:

FIG. 1A shows a front view of an exemplary system having a print bedwith 7 degrees of movement, independently controllable;

FIG. 1B shows a side view of the exemplary system of FIG. 1A;

FIG. 1C shows a top view of the exemplary system of FIG. 1A;

FIG. 1D shows a side view of a prototype set-up employing a mandrelconnected with the print bed;

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made to the embodiments of the invention, one ormore examples of which are set forth below. Each example is provided byway of an explanation of the invention, not as a limitation of theinvention. In fact, it will be apparent to those skilled in the art thatvarious modifications and variations can be made in the inventionwithout departing from the scope or spirit of the invention. Forinstance, features illustrated or described as one embodiment can beused on another embodiment to yield still a further embodiment. Thus, itis intended that the present invention cover such modifications andvariations as come within the scope of the appended claims and theirequivalents. It is to be understood by one of ordinary skill in the artthat the present discussion is a description of exemplary embodimentsonly, and is not intended as limiting the broader aspects of the presentinvention, which broader aspects are embodied exemplary constructions.

A 3D printer is generally provided, along with methods of itsconstruction and use. Generally, the 3D printer allows for printing ofcomposite parts with continuous fibers in multiple directions andorientations, which can lead to the production of composite parts. Thus,the provided 3D printer combines the advantages of traditional 3Dprinting using plastics with the strength and stiffness of compositeparts produced with methods such as vacuum injection. The 3D printer isparticularly suitable for printing ready-for-use duct work, conduit,tubing, piping, channeling, hollow-chambered structures and othersimilar structures by addressing the stiffness and strength shortcomingsthat would be associated with forming these parts with a conventional 3Dprinting technique, which would provide unreinforced polymer 3D printedparts. As an example, the provided 3D printer can be used inapplications to print thin-walled, complex shaped parts, which,heretofore could only be manufactured in a complex, multi-step process.Thus, the provided 3D printer and processes allows the 3D printing ofmulti-axial composite parts with multiple degrees of print freedom,opening the possibility of printing high performance parts with thecontinuous fiber reinforcement creating the required stiffness andstrength.

The 3D printer, according to one embodiment, utilizes a six (6) Degreesof Freedom (or more, including seven degrees of freedom) system thatallows the printing of fiber(s) in different directions and orientationsrelative to a plane perpendicular of a print bed, where in someinstances, the fiber is a continuous fiber. By the term “6 Degrees ofFreedom” refers to the freedom of movement in three-dimensional space ofthe print bed onto which the fibers are printed. Specifically, the printbed has six (6) independently controllably movements: threetranslational movements and three rotational movements. Thetranslational movements are up/down, left/right, and forward/backward,and the three rotational movements are typically referred to as pitch,roll, and yaw. The print head may be fixed relative to some degrees offreedom, such as up/down, or alternatively also exhibit six degrees offreedom. In some embodiments, added degrees of freedom can be achievedby the introduction of a mandrel on the print bed to which compositematerial is applied. Orientation of the mandrel, itself, may becontrolled relative to the print bed to provide added degrees of freedom(i.e., 7 degrees of freedom).

The various degrees of freedom of the print bed, and in some instances,the movement of an added mandrel, allow for complex introduction offiber(s) and/or composite materials into and/or within a work piece(e.g., object, part component, and the like) above and beyond what isachievable by a standard 3D printer. Instead of introduction of a fiberand/or composite material in a stepped-fashion to a work piece, theorientation, elevation, angle, and the like of a fiber(s) and/orcomposite material may be varied during the printing process to createcomplex printed formations/shapes within the work piece. For example,the fiber(s) and/or composite material could be applied as the print bedis periodically or continuously altered in direction/orientation tocreate a complex pattern of fiber(s) and/or composite material, such asfor example, a zigzag pattern in the work piece or bend or complex shapein the work piece that cannot be achieved by linear application ofmaterial as performed by traditional 3D printers. The continuousfiber(s) or composite material may even be twisted about itself bymanipulation of the print bed and/or an alternative mandrel relative tothe fiber(s) or composite material during application.

FIGS. 1A-1C shows an exemplary system 10 including a nozzle 12 having anextrusion tip 14 defining a translational point PT. The nozzle 12combines a formation material 16 and a continuous fiber 18 to form acomposite material 20. During printing, the composite material 20 isdeposited onto the printing surface 22 of the print bed 24 and/or amandrel (not shown) located on the printing surface, where the mandrelacts as a structural form to which the composite material is applied,and/or an existing work piece. The print bed 24 is moveable,independently with 6 degrees of freedom, as controlled by the controller26. As will be discussed later, the movement/orientation of an optionalmandrel may also be controlled relative to the print bed to provideadded degrees of freedom for further complex printing.

The print bed 24 is moveable in the x-direction (i.e., up/down withrespect to the translational point PT), in the y-direction (i.e.,laterally with respect to the translational point PT), and z-direction(i.e., cross-laterally with respect to the translational point PT). Theprint bed 24 can be moved translational, independently, by controller 26using the arm 28 connected to the receiver 30 of the print bed 24. Inparticular embodiments, the arm 28 can be formed from multiple segmentsconnected together at moveable joints (bending and/or rotating) to allowfor translational movement of the print bed 24 with respect to thetranslation point PT.

Additionally, the print bed 24 is rotationally movable about therotational point PR to allow roll (r), pitch (p), and yaw (w) rotationalmovement. The print bed 24 can be rotated in any direction,independently, by controller 26 using the arm 28 connected to thereceiver 30 of the print bed 24. Although shown as utilizing a rotationball 29 coupled to the receiver 30, any suitable connection can beutilized.

As shown in FIG. 1D, a mandrel 32 may be applied to the printing surface22 of the print bed 24. The mandrel 32 may act as a structural form towhich the fiber(s) and/or composite materials are applied to form thework piece. In some embodiments, the mandrel may be applied in astationary manner to the printing surface and move with the print bed 24of the printer. In some embodiments, the mandrel may be applied to asecond printing surface or positioned on a moveable arm that is separatefrom the print bed 24, so that the mandrel is moveable relative to theprint bed 24 to create further degrees of freedom beyond the six degreesof freedom achieved via the movable print bed. Alternatively, addeddegrees of freedom could be achieved via use of multiple print beds thatare each movable in six degrees of freedom relative to the base printbed 24, whereby controlled orientation of the base print bed 24 andcontrolled orientation of the added print beds creates further degreesof freedom.

In one embodiment, the controller 26 may comprise a computer or othersuitable processing unit. Thus, in several embodiments, the controller26 may include suitable computer-readable instructions that, whenimplemented, configure the controller 26 to perform various differentfunctions, such as receiving, transmitting and/or executing arm movementcontrol signals.

A computer generally includes a processor(s) and a memory. Theprocessor(s) can be any known processing device. Memory can include anysuitable computer-readable medium or media, including, but not limitedto, RAM, ROM, hard drives, flash drives, or other memory devices. Thememory can be non-transitory. Memory stores information accessible byprocessor(s), including instructions that can be executed byprocessor(s). The instructions can be any set of instructions that whenexecuted by the processor(s), cause the processor(s) to provide desiredfunctionality. For instance, the instructions can be softwareinstructions rendered in a computer-readable form. When software isused, any suitable programming, scripting, or other type of language orcombinations of languages may be used to implement the teachingscontained herein. Alternatively, the instructions can be implemented byhard-wired logic or other circuitry, including, but not limited toapplication-specific circuits. Memory can also include data that may beretrieved, manipulated, or stored by processor(s).

The computing device can include a network interface for accessinginformation over a network. The network can include a combination ofnetworks, such as Wi-Fi network, LAN, WAN, the Internet, cellularnetwork, and/or other suitable network and can include any number ofwired or wireless communication links. For instance, computing devicecould communicate through a wired or wireless network with the arm 28,the rotation ball 29, and/or the nozzle 12.

In one embodiment, the printer can include multiple nozzles. Forexample, a nozzle can be included to print wax-like material to supportthe formation material during the printing process.

In one particular embodiment, the controller 26 can include (or be incommunication with a computer that includes) supporting softwareprograms that can include, for example, computer aided design (CAD)software and additive manufacturing layering software as are known inthe art. The controller 26 can operate via the software to create athree-dimensional drawing of a desired structure and/or to convert thedrawing into multiple elevation layer data. For instance, the design ofa three-dimensional structure can be provided to the computer utilizingcommercially available CAD software. The structure design can then besectioned into multiple layers by commercially available layeringsoftware. Each layer can have a unique shape and dimension. The layers,following formation, can reproduce the complete shape of the desiredstructure.

For example, the printer can be accompanied with software to slicebeyond the current xyz slicing methodology used in industry. Forexample, 3D objects other than 3D Cartesian objects, such as aiso-parametric helically/spirally winded band around a duct, can bespirally sliced instead of sliced in a flat plane, to be able tospirally lay-down/print filament and/or slit tape/tow. Thus, theiso-parametrical slicing can be utilized with printing capability of the6 degrees of freedom.

In a traditional 3D printing system, the layer files are translated toprint head movements for applying material to a print bed to form thework piece. In the print system provided herein, the layer files arealso translated to print bed and/or mandrel movements to create thevarious layers and continuous thread patterns discussed herein viamovement of the print head and/or the mandrel.

Numerous software programs have become available that are capable ofperforming the presently specified functions. For example, AUTOLISP canbe used to convert AUTOCAD drawings into multiple layers of specificpatterns and dimensions. CGI (Capture Geometry Inside, currently locatedat 15161 Technology Drive, Minneapolis, Minn.) also can providecapabilities of digitizing complete geometry of a three-dimensionalobject and creating multiple-layer data files. The controller 26 can beelectronically linked to mechanical drive means so as to actuate themechanical drive means in response to “x,” “y,” and “z” axis drivesignals and “p,” “r,” and “w,” rotation signals, respectively, for eachlayer as received from the controller 26.

As stated, the composite material 20 includes a formation material 16and a continuous fiber 18. The continuous fiber 18 is discharged inconjunction with the formation material 20 such that the continuousfiber 18 is at least partially encased within the formation material 20to form the composite material 20, as shown. The formation material 16can be a metal, a polymeric material, etc. that is fed to the nozzle 12and is heated above the melting temperature of the material to softenand/or liquefy so as to flow through the extrusion tip 14 and form apartial or continuous coating on the continuous fiber 18, such that theformation material bonds with the outer surface of the continuous fiber.

The formation material 16 can be, for example, a gel, a high viscosityliquid, or a formable solid that can be extruded in the desired pattern.Formation materials likewise can be organic or inorganic. Formationmaterials can include, without limitation, polymers includingthermoplastic polymers or thermoset polymers (e.g., polyolefins,polystyrenes, polyvinyl chloride, elastomeric thermoplastics,polycarbonates, polyamides, etc.), eutectic metal alloy melts, clays,ceramics, silicone rubbers, and so forth. Blends of materials can alsobe utilized as the formation materials, e.g., polymer blends. Theformation materials can include additives as are generally known in theart such as, without limitation, dyes or colorants, flow modifiers,stabilizers, nucleators, flame retardants, and so forth.

The formation material is combined with a high strength continuousfiber(s) 18 prior to or during formation of the layer. The high strengthcontinuous fibers can be utilized as individual fibers or as bundles offibers, e.g., a roving. As used herein, the term “roving” generallyrefers to a bundle or tow of individual fibers. The fibers containedwithin the roving can be twisted or can be straight. Although differentfibers can be used in a roving, it can be beneficial in someembodiments, if a roving contains a single fiber type to minimize anyadverse impact of using fiber types having a different thermalcoefficient of expansion. The number of fibers contained in each rovingcan be constant or vary from roving to roving and can depend upon thefiber type. A roving can include, for instance, from about 500 fibers toabout 100,000 individual fibers, or from about 1,000 fibers to about75,000 fibers, and in some embodiments, from about 5,000 to about 50,000fibers.

The continuous fibers possess a high degree of tensile strength relativeto their mass. For example, the ultimate tensile strength of the fiberscan be about 3,000 MPa or greater. For instance, the ultimate tensilestrength of the fibers as determined according to ASTM D639 (equivalentto ISO testing method 527) is typically from about 3,000 MPa to about15,000 MPa, in some embodiments from about 4,000 MPa to about 10,000MPa, and in some embodiments, from about 5,000 MPa to about 6,000 MPa.Such tensile strengths may be achieved even though the fibers are of arelatively light weight, such as a mass per unit length of from about0.1 to about 2 grams per meter, in some embodiments from about 0.4 toabout 1.5 grams per meter. The ratio of tensile strength to mass perunit length may thus be about 2,000 Megapascals per gram per meter(“MPa/g/m”) or greater, in some embodiments about 4,000 MPa/g/m orgreater, and in some embodiments, from about 5,500 to about 30,000MPa/g/m.

The high strength fibers may be organic fibers or inorganic fibers. Forexample, the high strength fibers may be metal fibers (e.g., copper,steel, aluminum, stainless steel, etc.), basalt fibers, glass fibers(e.g., E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1-glass,S2-glass, etc.), carbon fibers (e.g., amorphous carbon, graphiticcarbon, or metal-coated carbon, etc.), nanotubes, boron fibers, ceramicfibers (e.g., boron, alumina, silicon carbide, silicon nitride,zirconia, etc.), aramid fibers (e.g., Kevlar® marketed by E. I. duPontde Nemours, Wilmington, Del.), synthetic organic fibers (e.g.,polyamide, ultra-high molecular weight polyethylene, paraphenylene,terephthalamide, and polyphenylene sulfide), polybenzimidazole (PBI)fibers, and various other natural or synthetic inorganic or organicfibrous materials known for reinforcing compositions. The materials usedto form the fibers can include various additives as are known in theart, e.g., colorants, etc.

Carbon fibers are particularly suitable for use as the continuousfibers, which typically have a tensile strength to mass ratio in therange of from about 5,000 to about 7,000 MPa/g/m.

The continuous fibers can generally have a nominal diameter of about 2micrometers or greater, for instance about 4 to about 35 micrometers,and in some embodiments, from about 5 to about 35 micrometers.

The continuous fibers are discharged in conjunction with the formationmaterial during the formation of an individual layer of the additivelymanufactured product structure such that the continuous fiber is atleast partially encased by the formation material. Any suitable methodfor combining the materials can be utilized, provided that thecontinuous fiber is adequately incorporated with the formation materialand bonding between the two materials can occur. The type of bond formedbetween the continuous fiber and the formation material can depend uponthe two materials involved. For instance a thermal bond, a chemicalbond, a friction bond, an electrostatic bond, etc. can be formed betweenthe two materials in order that the high strength continuous fiber is atleast partially encased by the formation material and the two componentswill be effectively bonded to one another. In some embodiments, both thecontinuous fiber and the formation material may be sufficiently heatedto promote admixing of the formation material and continuous fiber toform the composite material.

As will be appreciated from this disclosure, the continuous fiber may beany material having reinforcing characteristics. The continuous fibermay be formed of a plurality of fibers of either the same or differingmaterials. The formation material may be formed of one material or anadmixture of multiple materials. Further, the print head may beconfigured to apply one or multiple coatings of formation material onthe continuous fiber, either stacked on the other, overlapping orapplied at different positions on the surface of the continuous fiber.Further, the print head could be configured to advance several differentcontinuous fibers with different or the same formation materials,depending on the specifications required for formation of a work piece.In addition, the system could include multiple print heads configured toprovide either the same or different print media to a work piece, sothat different compositions of materials may be used to form the workpiece. For example, some print heads could be configured to eitheradvance different continuous fibers and/or formation materials toprovide different composition materials to be selectively applied to thework piece. In further or alternative embodiments, some print heads maybe configured to provide continuous fiber reinforced compositematerials, while other print heads provide non-reinforced printing mediato thereby provide a work piece that has selective reinforced sections.

Discharge of the continuous fiber from the print head can be achieved indifferent manners, depending on the application. In one embodiment, thecontinuous fiber may be advanced through the print head as part of anextrusion process, whereby the continuous fiber is “pushed” or urgedthrough the print head. In this embodiment, the continuous fiber isengaged with a driving system, such as a motorized friction drivewheel(s) or a forced air system, to advance the continuous fiber throughthe print head. The continuous fiber enters an input orifice in theprint head and is advanced toward the extrusion tip 14 of the nozzle 12.The formation material 16 is heated above the melting temperature of theformation material to soften and/or liquefy so as to flow through theextrusion tip 14 and form at least a partial coating on the continuousfiber 18, as the continuous fiber is advanced from the print head andonto the printing surface 22, a mandrel 32, and/or an existing workpiece on the print bed 24. By movement of the print bed 24 and/or themandrel relative to the print head, work pieces can be formed byadditive application of the composite material 20 onto the printingsurface 22, mandrel, and/or existing work piece.

As an alternative to advancing the continuous fiber by push or urgingthe fiber through the print head, the continuous fiber may be advancedby a pultrusion operation, whereby the continuous fiber is drawn orpulled from the tip of the nozzle. In this embodiment, the contact pointof the composite material on the printing surface 22 of the print bed24, an alternative mandrel 32 located on the print bed 24, and/or anexisting work piece located on the print bed creates an anchor (e.g., afixed, contact, gripping point, and the like) that allows for thecomposite material 20 to be pulled from the print head as the print bed24, mandrel 32, and/or existing work piece is moved relative to theprint head to form the finished work piece. In this embodiment, usingthe movement of the print bed and/or mandrel allows for precise controlof the advancement of the composite material 20 from the print head.

Drawing or “casting on” of the composite material 20 onto the printingsurface 22, mandrel 32 and/or existing work piece to begin the printingprocess can be accomplished by various methods. For example, thecomposite material 20 could be connected or adhered to a needle or othertype structure that can draw the composite material from the print headand apply it to the printing surface, mandrel, and/or existing workpiece. As an alternative, the nozzle of the print head may be broughtinto contact with the printing surface 22 of the print bed 24, themandrel 32, and/or the existing work piece so as to contact thecomposite material 20, whereby either the composite material itself orthe formation material 16 surrounding the continuous fiber 18 in themelted state adheres to the printing surface 22, mandrel 32, and/or theexisting work piece creating an anchor for pulling the compositematerial 20 from the print head.

The rate of advancement of the continuous fiber through the print head,the temperature of the formation material, and/or in some instances, thetemperature of the printing surface 22 of the print bed 24, the mandrel32, and/or the existing work piece on the print bed require some levelof control to ensure that the continuous fiber 18 receives aconsistent/desired coating and that the composite material 20 is appliedto either the printing surface 22, mandrel 32, and/or existing workpiece in a manner to adhere to same. For example, the temperature of theformation material 16 and the rate of movement of the print bed and/ormandrel may be controlled to ensure that the composite material 20 isapplied in a manner to allow for proper adherence of the compositematerial 20 to the printing surface 22, mandrel 32, and/or existing workpiece. In some instances, the printing surface and/or the mandrel and/orthe existing work piece on which the composite material 20 is appliedcan also or alternatively be temperature controlled for this purpose. Ingeneral, the rate of application and temperature of the formationmaterial 16 on the continuous fiber 18 are controlled to ensure that thecoating is applied in a desired manner on the continuous fiber and thatthe composite material 20 is drawn from the print head is a consistentmanner.

Tensioning of the composite material may also be required for properadvancement onto the printing surface, mandrel, and/or existing workpiece. Tensioning systems can take many forms and be located atdifferent positions in the process to provide proper tensioning of thecontinuous fiber and/or the composite material. For example, a spoolmaintaining the continuous fiber could be fitted on a tensioning system,such as a rotational break or clutch that impedes rotation of the spoolas continuous fiber is meted from the spool to provide tensioning.Similarly, the print head may include a tensioning system, such asrestrictive pulleys, clutch, friction element or the like to applytension to the continuous fiber.

It is also contemplated that the proposed printer could be equipped toperform both “push” and pultrusion of the continuous fiber to advancethe continuous fiber through the print head. In this embodiment, theremay be drive means associated with the print head to advance thecontinuous fiber through the print head assisted by a pulling effect ofthe movement of the print bed, mandrel, and/or existing work piece onthe composite material as it is advanced.

As mentioned above, the composite material 20 may be applied to amandrel, where the mandrel operates as a form, support and/or pattern ofthe work piece to be manufactured from the composite material 20. Themandrel aids in shaping of the work piece being printed as the compositematerial is applied to the mandrel. After printing is complete, and theprinted work piece has at least partially cured, the mandrel can beremoved from the work piece, such as by eroding, dissolving, breakings,shrinking, or other contemplated procedures for removing either portionsof or the entire mandrel.

The above description discloses an embodiment of the system thatincorporates both a print head capable of advancing a continuous fiberand a print bed that is moveable with six degrees of freedom. It isunderstood, however, that embodiments are contemplated whereby a printhead capable of advancing a continuous fiber may be incorporated into asystem that comprises a stationary print bed. Alternatively, embodimentsare contemplated whereby a system is employed that includes a print bedthat is moveable with six degrees of freedom in combination with atraditional 3D print head that does not advance a continuous fiber.

EXAMPLES

A prototype set-up was developed that includes a 6 degrees of freedomrobot with integrated industrial level controls to operate the extruder(print head), hotbed and temperature sensors. Integration of hardwareand software has been achieved. Fiber reinforced material system hasbeen defined and experiment preparations are in progress to do solventbased filament production.

A KUKA KR6 based robotic system was developed to print thin walledcontinuous carbon reinforced ULTEM ducting for use in vehicles. Thesystem allows printing of carbon fiber reinforced ULTEM of thin walledducts with fibers printed not only in the plane of the cross-section ofthe duct but also in directions with angles with respect to thecross-sectional plane. This is in contrast to current 3D printingsystems based on printing layer by layer and therefore allowing onlyfibers in the cross-sectional plane. The system may offer seven (7)degrees of freedom (3 translations and 3 rotations related to the robotand 1 degree of freedom imparted by a separate mandrel). The system isfed with a material system compliant to the Fire, Smoke and Toxicity(FST) requirements specified by FAA and EASA. The system has multipleprinting heads to be able to print parts that are designed to be builtfrom a combination of unreinforced, chopped fiber reinforced andcontinuous fiber reinforced materials. In addition a printing head issupplied able to print support material that can be removed afterprinting. This support material serves as an optional stabilizer forlong, thin walled parts.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood the aspects of the various embodiments may beinterchanged both in-whole or in part. Furthermore, those of ordinaryskill in the art will appreciate that the foregoing description is byway of example only, and is not intended to limit the invention sofurther described in the appended claims.

What is claimed is:
 1. A system for printing a three-dimensional object,the system comprising: at least one print head configured to receive acontinuous fiber and at least partially encase the continuous fiber witha formation material to create a composite material; and at least oneprint bed comprising a printing surface onto which the compositematerial may be selectively applied to form a work piece.
 2. The systemaccording to claim 1, further comprising: a drive means associated withsaid at least one print head for advancing the continuous fiber throughthe at least one print head for application with the formation material.3. The system according to claim 1, wherein the continuous fiber isadvanced through the at least one print head by pulling of the compositematerial via a connection of the composite material with one or more ofa printing surface of the at least one print bed, a mandrel, and/or anexisting work piece.
 4. The system according to claim 1, wherein said atleast one print bed is configured to move in at least six differentdegrees of freedom, and said system further comprising: one or moredrive means connected to said at least one print bed for movement of theat least one print bed in or more of the six different degrees offreedom; and a controller in communication with said one or more divemeans.
 5. The system according to claim 1, wherein the at least oneprint bed is movable along x, y, z coordinate plains and rotatable aboutpitch, row, and yaw axes.
 6. The system according to claim 1, furthercomprising: at least one mandrel for receiving the composite materialand providing a form for shaping of the composite material into aselected shape.
 7. A system for printing a three-dimensional object, thesystem comprising: at least one print bed comprising a printing surfaceonto which print media is applied to form a work piece, wherein said atleast one print bed is configured to move in at least six differentdegrees of freedom; and at least one print head positioned relative tosaid at least one print bed and configured to advance print mediathereon.
 8. The system according to claim 7, further comprising: one ormore drive means connected to said at least one print bed for movementof the at least one print bed in one or more of the six differentdegrees of freedom; and a controller in communication with said one ormore dive means.
 9. The system according to claim 7, wherein the atleast one print bed is movable along x, y, z coordinate plains androtatable about pitch, row, and yaw axes.
 10. The system according toclaim 7, wherein said at least one print head is configured to receive acontinuous fiber and at least partially encase the continuous fiber witha formation material to create a composite material.
 11. The systemaccording to claim 10, further comprising: a drive means associated withsaid at least one print head for advancing the continuous fiber throughthe at least one print head for application to the printing surface ofthe at least one print bed.
 12. The system according to claim 10,wherein the continuous fiber is advanced through the at least one printhead and onto the printing surface of the at least one print bed bypulling of the composite material via a connection of the compositematerial with the printing surface of the at least one print bed. 13.The system according to claim 7, further comprising: at least onemandrel located on said at least print bed for receiving the compositematerial and providing a form for shaping of the composite material intoa selected shape.